Mailpiece reject processing and labeling

ABSTRACT

Improvements are disclosed for further processing of a mail piece initially rejected from an automatic sorting machine. Supplemental automated processes are applied to read a bar code from the front of the piece, or read an ID Tag from the back of the piece. New labels can be applied to the front and or back sides of the piece automatically. Newly resolved address information can be applied the piece, following which it preferably is returned into the main sorting stream so that manual sorting is reduced, resulting in cost savings.

RELATED APPLICATIONS

This application claims priority from U.S. Provisional Application No.60/856,425 filed Nov. 1, 2006, and incorporated herein by thisreference.

COPYRIGHT NOTICE

© 2006-2007 RAF Technology. A portion of the disclosure of this patentdocument contains material which is subject to copyright protection. Thecopyright owner has no objection to the facsimile reproduction by anyoneof the patent document or the patent disclosure, as it appears in thePatent and Trademark Office patent file or records, but otherwisereserves all copyright rights whatsoever. 37 CFR § 1.71(d).

TECHNICAL FIELD

This invention pertains to methods and apparatus for sorting andhandling items, such as mail pieces, and more specifically toimprovements in reject processing and labeling of mail piece items so asto reduce expensive manual sorting.

BACKGROUND OF THE INVENTION

FIG. 1 is a front (address side) of mailpiece 100 having several areasreserved for addressing. With reference to FIG. 1, mailpiece 100 haspostage area 102, optical character recognition (OCR) read area 106,POSTNET clear zone 108, and return address area 104. By way of example,if address 314 (FIG. 3) is located within OCR read area 106, a multilineoptical character reader (MLOCR) may be able to resolve address 314 andprint a Postal Numeric Encoding Technique (POSTNET) barcode, such asPOSTNET barcode 300 (FIG. 3), in POSTNET clear zone 108.

With reference to FIG. 2, ID Tag clear zone 202 is on the rear side(back side) of mailpiece 200. A unique ID Tag (not shown) may be appliedto the back of mailpiece 200 (in ID Tag clear zone 202) to allow data tobe matched with mailpiece 200 in subsequent automated operations. Forexample, if address 314 cannot be read by an OCR, an image may becaptured and sent to a Remote Encoding Center (REC). A keyer (manualinput person) at the REC can input data, such as the zip code 304 andplus-four code 306, into a database. The ID Tag allows the data to bematched with the specific mailpiece and POSTNET barcode 300 to beapplied downstream (e.g. by an Output Sub-System).

Referring now to FIG. 3, POSTNET barcode 300 corresponds to address 314.Frame bars 302 and 312 begin and end the barcode sequence. POSTNETbarcode 300 is an eleven-digit delivery point code representing zip codein field 304, plus-four code in field 306, delivery point code at field308, and finally a check digit 310. Delivery point code 308 may be aspecific set of digits between 00 and 99 such as the last two digits ofa street address. The delivery point code 308, zip code 304, andplus-four code 306 result in a unique, numeric identifier for nearlyevery address served by the United States Postal Service (USPS). Checkdigit 310 essentially is a form of redundancy check used for errordetection. Other POSTNET barcodes may also be applied to POSTNET clearzone 108, such as a nine-digit barcode representing zip code 304 andplus-four code 306, a five-digit barcode representing zip code 304, or a4-state barcode where the bars represent four states (e.g., fourlengths) instead of just two states (e.g., two lengths).

Although bar codes are currently in use by the USPS and are discussedherein by way of example, the inventive concepts disclosed in thisapplication could be applied as well to systems and methods that employother machine-readable or optically readable codes or markings in thePOSTNET clear field and/or in the ID Tag field. We will use the termmachine-readable indicia or “MRI” in the claims in this broader sense;MRI includes but is not limited to bar codes. It applies as well toother markings that can be applied to an article by automated machinery(printed, sprayed, etc.) and conversely can be recognized or read bymachine.

Using an automated process to sort mailpieces is generally more costeffective than using manual labor. However, if address 314 is notresolvable (e.g., by an OCR or REC), the mailpiece must be manuallysorted. This is a relatively expensive process. The need remains forimprovements in reject processing and labeling of mail piece items.

SUMMARY OF THE INVENTION

According to one embodiment, instead of sending the mailpieces through amanual sort process, the mailpieces may be sent to a labeling machinehaving an on-board OCR engine, such as a Reject Encoding Machine (REM).The REM may over-label POSTNET clear zone 108 (e.g., apply a label overthe clear zone). In addition, if a bad ID Tag is identified (e.g., theID Tag cannot be resolved), ID Tag clear zone 202 may also beover-labeled. The REM may also incorporate an image capture device thatmay capture a resolvable image (e.g., the image capture device couldhave a higher resolution or use different optics, hardware, or softwarethat allows a different image of the mailpiece to be captured).Furthermore, the OCR may be running different algorithms (e.g.,orthogonal OCR engines). Accordingly, the image capture device or OCR ofthe REM may be able to resolve address 314 and apply barcode 300. Themailpiece can then be sent to a Delivery Bar Code Sorter (DBCS) forautomated sorting. However, if the REM cannot resolve address 314,POSTNET clear zone 108 or ID Tag clear zone 202 may still beover-labeled for downstream processing. Therefore, the REM may savecosts in terms of time and money by reintroducing mailpieces into theautomated stream instead sorting the mailpieces by hand.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of an envelope showing a POSTNET clear zone;

FIG. 2 is a rear view of an envelope showing a ID Tag clear zone;

FIG. 3 is a POSTNET barcode illustrating an eleven-digit delivery pointbarcode;

FIG. 4 is a flow chart illustrating a process for over-labeling a clearzone;

FIG. 5 is a flow chart illustrating a process for over-labeling a clearzone according to one embodiment;

FIG. 6 is a flow chart illustrating a process for handling first passdelivery point sequence rejects;

FIG. 7 is a flow chart illustrating a process for first pass deliverypoint sequence rejects according to one embodiment;

FIG. 8 is a flow chart illustrating a process for attempting to read andbarcode mailpieces;

FIG. 9 is a flow chart illustrating a process for resolving an addressof a mailpiece having an improperly aligned insert according to oneembodiment;

FIG. 10 is a flow chart illustrating a process for delivering mailhaving a high degree of gloss; and

FIG. 11 is a flow chart illustrating a process for delivering mailhaving a high degree of gloss according to one embodiment.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

Address 314 may not be resolvable because a bad image was captured ofthe mailpiece. For example, the image may not be readable, the image maynot contain an address (e.g., the image capture device was not properlyaligned or an insert was not aligned with a window of an envelope),there may not be sufficient contrast in the image, or the captured textmay be too light. In addition, the OCR may not incorporate the correctalgorithm needed to resolve the address.

According to one embodiment, instead of sending the mailpieces through amanual sort process, the mailpieces may be sent to a labeling machinehaving an on-board OCR engine, such as a Reject Encoding Machine (REM).The REM may over-label POSTNET clear zone 108 (e.g., apply a label overthe clear zone). In addition, if a bad ID Tag is identified (e.g., theID Tag cannot be resolved), ID Tag clear zone 202 may also beover-labeled. The REM may also incorporate an image capture device thatmay capture a resolvable image (e.g., the image capture device couldhave a higher resolution or use different optics, hardware, or softwarethat allows a different image of the mailpiece to be captured).Furthermore, the OCR may be running different algorithms (e.g.,orthogonal OCR engines). Accordingly, the image capture device or OCR ofthe REM may be able to resolve address 314 and apply barcode 300. Themailpiece can then be sent to a Delivery Bar Code Sorter (DBCS) forautomated sorting. However, if the REM cannot resolve address 314,POSTNET clear zone 108 or ID Tag clear zone 202 may still beover-labeled for downstream processing. Therefore, the REM may savecosts in terms of time and money by reintroducing mailpieces into theautomated stream instead sorting the mailpieces by hand.

Labeling Machine Having an On-Board OCR Engine to Process Rejects

A Delivery Bar Code Sorter (DBCS) sorts mail in the order of a mailcarrier's delivery route. However, some mailpieces are not processed ona DBCS because POSTNET barcode 300 cannot be resolved. For example,POSTNET barcode 300 may be illegible, due to smudging. In addition,noise or interference, such as stray marks, may be present in POSTNETclear zone 108. With reference to FIG. 4, one process is described thatinvolves over-labeling an unresolved barcode to create a new clear zone.At step 400, mailpieces are fed into DBCS 422, which attempts to resolvePOSTNET barcode 300 in POSTNET clear zone 108. If barcode 300 isresolved (e.g., zip code 304, plus-four code 306, delivery point code308, and check digit 310 are read by a barcode scanner), DBCS 422 sortsthe mailpieces at step 420 using barcode 300.

However, if barcode 300 cannot be resolved at step 400, DBCS 422 mayattempt to resolve an ID Tag in ID Tag clear zone 202 at step 432. Ifthe ID Tag is resolvable, at step 434 DBCS 422 will attempt to perform adata lookup to see whether any data has been stored for the associatedID Tag, such as a resolved address. At step 420, if data is found, themailpieces may be sorted using the ID Tag data. At step 418, the mailcarrier delivers the sorted mailpieces.

DBCS 422 may also attempt to resolve barcode 300 and the ID Tag for eachmailpiece. The data associated with barcode 300 (e.g., zip code 304 andplus-four code 306) can be compared with any data that has been storedfor the associated ID Tag. If the data are not consistent, the dataassociated with barcode 300 may be used instead of the ID Tag data(e.g., data loaded for the ID Tag). On the other hand, if barcode 300 isnot resolvable, the ID Tag data may be used.

If, however, barcode 300 cannot be resolved at step 400 and the ID Tagis not resolvable or the ID Tag data is not available at step 432, themailpieces will be placed in a reject bin of DBCS 422. At step 402, therejected mailpieces can be sent to and run through Letter Mail LabelingMachine (LMLM) 424. At step 404, LMLM 424 may over-label (e.g., place anew label) POSTNET clear zone 108. In addition, the mailpiece may be runthrough LMLM 424 with a rear side of mailpiece 200 facing a labeler (notshown) to over-label ID Tag clear zone 202. Over-labeling step 404provides a clear zone for barcode 300 to be applied in POSTNET clearzone 108 and for the ID tag to be applied in ID Tag clear zone 202.

At step 406, the newly labeled mailpieces may be sent to and run througha system running in an Input Sub-System (ISS) mode 426 (e.g., a MLOCR orAdvanced Facer Canceller System may be running in ISS mode or a DBCS mayhave been modified with an ISS kit). At step 408, ISS 426 attempts toresolve (e.g., determine a full destination barcode 300) address 314. Ifaddress 314 is resolved, barcode 300 is applied (e.g. printed orsprayed) in POSTNET clear zone 108 at step 410. In addition, an ID Tagmay be applied to ID Tag clear zone 202 if one is needed (e.g., themailpiece did not have an ID Tag). The mailpieces can be run throughDBCS 422 again for sorting. However, if at step 408, address 314 is notresolvable, another attempt may be made at resolving the address at step412 (which may be on a separate machine 428). This may occur using aremote character recognition (RCR), which typically takes longer (e.g.,30 seconds) and uses advanced OCR algorithms. In addition, an image ofOCR read area 106 may be sent to a REC. If address 314 is resolvable atstep 412, barcode 300 may be applied at step 414 in POSTNET clear zone108. The mailpieces can be run through DBCS 422 again for sorting.However, if address 314 is not resolvable at step 412, the mailpiecescan be sent to a manual sort center 430 for sorting by hand (step 416).At step 418, the mail carrier delivers the hand sorted mailpieces.

With reference to FIG. 5, a process according to another embodimentinvolves over-labeling and applying barcode 300 in one step. At step500, mailpieces are fed into DBCS 524, which attempts to resolve POSTNETbarcode 300 in POSTNET clear zone 108. If barcode 300 is resolved, DBCS524 sorts the mailpieces at step 522 using barcode 300. However, ifbarcode 300 cannot be resolved at step 500, DBCS 524 may attempt toresolve an ID Tag in ID Tag clear zone 202 at step 532. If the ID Tag isresolvable, at step 532 DBCS 524 will attempt to perform a data lookupto see whether any data has been stored for the associated ID Tag, suchas a resolved address. At step 522, if data is found, the mailpieces maybe sorted using the ID Tag data. At step 520, the mail carrier deliversthe sorted mailpieces.

DBCS 524 may also attempt to resolve barcode 300 and the ID Tag for eachmailpiece. The data associated with barcode 300 (e.g., zip code 304 andplus-four code 306) can be compared with any data that has been storedfor the associated ID Tag. If the data are not consistent, the dataassociated with barcode 300 may be used instead of the ID Tag data(e.g., data loaded for the ID Tag). On the other hand, if barcode 300 isnot resolvable, the ID Tag data may be used.

If, however, barcode 300 cannot be resolved at step 500 and the ID Tagis not resolvable or the ID Tag data is not available at step 532, themailpieces will be placed in a reject bin of DBCS 524. At step 502, therejected mailpieces can be sent to and run through a labeling machinehaving an on-board OCR engine, such as Reject Encoding Machine (REM)526. In addition, other mailpieces may be routed to REM 526. Forexample, if a system running in ISS mode is unable to resolve address314 (e.g., the image is bad, the image is of insufficient quality, orthe OCR does not incorporate the correct algorithm needed to resolve theaddress), REM 526 may be able to resolve the address using a new imageacquisition and advanced OCR algorithms. At step 504, REM 526 attemptsto resolve address 314. If address 314 is resolved, a new label (step506) and barcode 300 (step 508) can be applied in POSTNET clear zone 108in one step. However, other methods may be used to over-label POSTNETclear zone 108. For example, barcode 300 could be applied to the labelbefore it is applied to POSTNET clear zone 108 of mailpiece 100. Inaddition, the POSTNET clear zone 108 of the mailpieces may otherwise berepaired. For example, POSTNET clear zone 108 could be resurfaced andbarcode 300 applied to the new surface. Furthermore, if the POSTNETclear zone 108 does not need repair (such as when mailpieces are sent toREM 526 because address 314 is not resolvable), REM 526 may resolve theaddress and apply barcode 300. The mailpieces can be run through DBCS524 again for sorting. Accordingly, sending the mailpieces to REM 526provides for a quick turnaround and may allow the mailpieces to bere-run on DBCS 524 while DBCS 524 machine is still processing the batchof mailpieces from which the rejected mailpieces came (e.g., a firstpass of Delivery Point Sequence (DPS) on a particular zone).

However, if at step 504, address 314 is not resolvable, a new label canbe applied to POSTNET clear zone 108 at step 510. Furthermore, the IDTag may be resolved by REM 526 and a database may be populated withinformation regarding the mailpiece. For example, if address 314 or partof address 314 (e.g., zip code 304 or plus-four code 306) were resolvedby REM 526, the resolved address or partial data associated with the IDTag may be stored. In addition, the mailpiece may be run through REM 526with rear side of mailpiece 200 facing a labeler (not shown) toover-label ID Tag clear zone 202. If REM 526 was fitted with an ID Tagsprayer, an ID Tag may be applied to ID Tag clear zone 202. At step 514,a RCR or REC may attempt to resolve address 314 (this may be done on aseparate machine 528). If resolved, barcode 300 may be applied at step516 to POSTNET clear zone 108. The mailpieces can be run through DBCS524 again for sorting. However, if address 314 is not resolvable at step514, the mailpieces can be sent to a manual sort center 530 for sortingby hand (step 518). At step 520, the mail carrier delivers the handsorted mailpieces. Therefore, if address 314 is successfully resolved(e.g., read) at step 504 and barcoded (steps 506 and 508), greaterefficiencies may be achieved. For example, mailpieces initially rejectedby DBCS 524 may be sorted more quickly and with less manual labor.

Reject Processing of First Pass DPS Rejects

As previously discussed, a DBCS sorts mail in the order of a mailcarrier's delivery route. This order is called the Delivery PointSequence (DPS) and barcode 300 having the DPS allows for automatedsorting from posting to delivery. Once mailpieces are prepared withbarcode 300 or received by a serving processing center with barcode 300,the mailpieces must be prepared for DPS. This can be done by sorting themailpieces to a zone or a zip code range. The zoned mail can be run on aDBCS to be placed in DPS, which generally requires two passes on theDBCS. The first pass sorts all mail by delivery stop mixing the mail forall carriers in that zone. The second pass takes all the mixed carriermail for each delivery stop and separates it by carrier. On this secondpass, the sort plan dedicates one pocket (e.g., bin of the DBCS) percarrier and the mail is sorted in the precise order that carriertraverses their route.

By way of analogy, a deck of shuffled cards may be sequenced using 13pockets and two passes through the cards. During the first pass, thecards can be sorted by rank (e.g., aces, twos, threes, etc.) into 13pockets with no regard to suit. At the end of the first pass, all thecards in the first pocket would be aces, all the cards in the secondpocket would be twos, and all the cards in the last pocket would bekings. During the second pass, the four cards in the first pocket wouldbe fed out of the pocket. Immediately thereafter, the four cards in thesecond pocket would be fed out. Each pocket would be emptied in asimilar manner. Accordingly, during the second pass the cards can beread and resorted into four pockets by suit with no regard to rank. Thefour aces would end up on the bottom of each of the fourth pocketsbecause these are the first four cards fed out. The twos would bestacked upon each respective ace and so forth. Upon completion asequenced deck of cards is obtained by sweeping the cards from left toright.

By way of another example, if there are ten carriers in zone 20007, thefirst pass would assign the first pocket on a DBCS to the first stop ordelivery point for all ten carriers, the second pocket for all of theirsecond stops and so forth. Even though the DBCS mixes carriers in eachpocket, it ensures that each pocket contains the same stop number foreach route. Then the mail in each bin is removed in order from the DBCSand run separately, in order as a second pass. The second pass sorts thecontents of each first-sort output bin by carrier. Thus, all the mailfor the first stop for the first carrier goes to bin 1, for the firststop for carrier 2 to bin 2, and so on. Then each subsequent output binof the first sort is run. The DBCS thus sorts each individual carrier'smail into a separate pocket—ten pockets in all for all ten carriers.Accordingly, all the mail is in delivery sequence order for eachcarrier.

However, as previously discussed, some barcodes 300 may not be resolvedby the DBCS which requires the mailpieces to be manually sorted.Referring now to FIG. 6, if barcode 300 is not resolvable (step 600),the mailpieces are manually sorted. At step 602, one or more individualsmust read and hand sort the mailpieces. In fact, the mailpieces mayactually be manually sorted three times: (1) at the serving processingcenter (to send it to the delivery postal center); (2) at the receivingdelivery postal center (to sort it to the individual carrier); and (3)by the delivery carrier to sort the mailpieces in the order of theirdelivery route. If, at step 600, barcode 300 of each mailpiece isresolved, all mailpieces may be sorted by zip code range at step 606,for example. At step 608, a first pass of the mailpieces may be run on aDBCS, which may take one or more hours to complete. At step 610, themailpieces can be sorted by delivery stop. At step 612, a second pass isrun on the DBCS, which further sorts the mailpieces by carrier (step614). At step 604, the mail carrier delivers the sorted mailpieces.

Another process according to one embodiment involves providing barcode300 on mailpieces that would otherwise go through a manual sort asdescribed with reference to FIG. 7. The DPS sorting process may occur ateach serving mail processing center for the carrier offices in thatservice area. At step 700, all mailpieces may be sorted by zip coderange, for example. At step 702, a first pass of the mailpieces may berun on a DBCS. An attempt to resolve barcode 300 is made at step 704. Ifbarcode 300 is not resolvable, the mailpieces can be sent to and runthrough a labeling machine having an on-board OCR engine, such as aReject Encoding Machine (REM) at step 714. The REM resolves address 314at step 716. At step 718, a label can be placed in POSTNET clear zone108 and barcode 300 may be applied in POSTNET clear zone 108. However,other methods may be used to over-label POSTNET clear zone 108. Forexample, barcode 300 could be applied to the label before it is appliedto POSTNET clear zone 108 of mailpiece 100. In addition, instead ofapplying a label, POSTNET clear zone 108 could be resurfaced and barcode300 applied to the new surface. Accordingly, mailpieces that wouldotherwise go through a manual sort (possibly three times) can bereturned to the DBCS in time (e.g., the first pass sort may take one ormore hours) to be included in a first pass sort. However, if barcode 300of each mailpiece was resolved at step 704, the mailpieces can be sortedby delivery stop at step 706. At step 708, a second pass can be run onthe DBCS, which further sorts the mailpieces by carrier (step 710). Atstep 712, the mail carrier can deliver the sorted mailpieces.

Read Reject Processing OSS Rejects Having Window Inserts

As previously discussed, a DPS barcode (such as barcode 300) allows mailto be sorted in the order of a mail carrier's delivery route. However,if address 314 is not resolvable by a system running in ISS mode,barcode 300 will not be applied to mailpiece 100. Mailpieces without abarcode must be manually sorted resulting in inefficiencies for the USPSand possibly delaying the delivery of the mailpieces. Sometimes address314 is not resolvable because an image of address 314 is not readable.For example, the image of address 314 may not provide sufficientinformation for the OCR to resolve the address (e.g., the address may beobscured or the print may be too fine to read). In addition, address 314may not be resolved on mailpieces having window inserts (e.g., a windownormally aligned with address 314). For example, the contents (e.g.,inserts) of mailpiece 100 may shift within mailpiece 100 obscuringaddress 314 (e.g., address 314 may fall below the window renderingaddress 314 unreadable).

With reference to FIG. 8, a process is described that attempts to readand barcode mailpieces. At step 800, mailpieces are run on a systemrunning in ISS mode. An image of the mailpiece (e.g., OCR read area 106)may be captured at step 802 and an ID Tag may be applied to ID Tag clearzone 202 at step 804. If the image does not contain an address, themailpiece would be placed in a reject bin and manually sorted at step808. The manual sort step includes reading and hand sorting themailpieces. The mailpieces must be manually sorted again at a receivingcarrier station if the mailpiece is to be delivered in the same city. Ifthe mailpiece is being sent to a different city, the mailpieces need tobe manually sorted again at a receiving processing center and a carrierstation where a clerk sorts the mailpieces by carrier. The carrier thensorts the mailpieces in the order of delivery on the carrier's route anddelivers the mailpieces at step 810.

If an address is in the captured image at step 806, the address isextracted from the image at step 812. At step 814, if an address isresolvable on-line (e.g., on the system running in ISS mode) barcode 300may be applied in POSTNET clear zone 108 (step 832). The mailpieces canbe sorted using barcode 300 at step 834 and delivered at step 810.However, if at step 814 the address is not resolvable, the mailpiecesmay be run on a backend remote character recognition (RCR) at step 816.The RCR typically uses advanced OCR algorithms but may take longer(e.g., 30 seconds) to resolve the address. If address 314 is resolvableat step 818, the resolved address 314 may be stored in a database alongwith the ID Tag associated with the mailpiece. When the mailpieces arerun again on an Output Sub-System (OSS) at step 828, the resolvedaddress associated with the ID Tag on the mailpiece is loaded (step 830)and barcode 300 may be applied at step 832 in POSTNET clear zone 108.The mailpieces can be run through a sorting machine (such as a DBCS) atstep 834 and delivered at step 810.

If address 314 is not resolvable at step 818, the mailpieces withunresolved addresses are collected at step 820, such as in a reject bin.An image of OCR read area 106 may be sent to a remote encoding center(REC) at step 822 where another attempt to resolve address 314 is made.If address 314 is resolved at step 824, the resolved address associatedwith the ID Tag on the mailpiece is stored at step 826. The mailpiececan be run on an OSS at step 828 as previously described. However, ifaddress 314 cannot be resolved by the REC at step 824, the mailpiecesmay be sent to a manual sort center for sorting by hand (step 808). Atstep 810, the mail carrier delivers the hand sorted mailpieces.

With reference to FIG. 9, a process according to one embodiment attemptsto read and barcode mailpieces having an unresolvable address 314 byrunning the mailpieces on a machine utilizing an advanced OCRrecognition system in conjunction with a short distance image capturefeed section, such as a reject encoding machine (REM). The REM mayutilize a proprietary on-board OCR system in conjunction with a shortdistance feed section that feeds mailpieces to an image capture device,such as a camera, for imaging. An image may be provided for a “no image”OSS reject that is “no image” because the insert has fallen below amailpiece window rendering address 314 unreadable.

At step 900, the mailpieces may be inverted by an operator. In addition,the mailpieces may be automatically inverted by a device, such as anautomatic inverter. For example, a vacuum may be applied to themailpiece, allowing the mailpiece to be rotated by a stepper motor orother rotating device. In addition, a gripper (e.g., one attached to anarm of a robot) may rotate the mailpiece. While this could involverotating the mailpieces 180 degrees, the mailpieces may also be rotatedby different degrees, such as 90 degrees (or 270 degrees) if an inserthas shifted laterally. At step 902, the mailpieces are agitated in anattempt to align address 314 with the window of the mailpiece. Theagitation process may involve shaking the mailpieces on a jogger orshaking table. At step 904 the mailpieces are returned to an uprightposition. The mailpieces may be inverted manually (e.g., by an operator)or automatically. While this may involve rotating the mailpieces 180degrees, as previously described, other degrees of rotation may beprovided. At step 904, a gentile motion may be needed to ensure theinsert does not misalign again. Steps 900, 902, and 904 have ideallycaused many of the inserts to return to a visible position in thewindow. In addition, the leading edge of the mailpieces are still linedup for imaging.

At step 906, mailpieces having an unreadable image or no image OSSrejects are run on a REM. The mailpieces can be transferred to the imagecapture device using a feeder having a short track at step 908. A shorttrack may prevent the inserts from becoming misaligned before the imagecapture device acquires an image of address 314. For example, a track ofeight to nine inches may be short enough to prevent the inserts frombecoming misaligned while a length of four or more feet may be too long(allowing the inserts to settle so that address 314 is no longer visiblethrough the window). However, the track may be longer if a mechanism toprevent the shifting of the insert is used. By way of example, rollersmay be used to apply pressure to both sides of the mailpieces, therebyinhibiting the inserts from shifting during travel. At step 910, address314 is resolved by the REM and barcode 300 is applied to POSTNET clearzone 108 at step 912. The mailpieces can then be sorted at step 914 anddelivered at step 916.

Shiny Mail Processing

Shiny mail (e.g., mail with a high degree of gloss) can make a surfaceof the mailpiece non-porous and resistant to ink from both the barcode300 sprayers and ID Tag sprayers. When barcode 300 or the ID Tag isapplied to shiny mail, the barcode may smudge causing rejection by aPOSTNET verifier or an ID Tag reader and thereby become rejects on anISS, OSS, DBCS, or any other equipment that must read barcode 300, theID Tag, or any other barcode.

With reference to FIG. 10, a process is described that attempts toover-label shiny mailpieces. At step 1000, mailpieces may be identifiedas shiny. This could occur as soon as the mailpieces arrive by the mailhandler (e.g., on their dock). If the shiny mail is not identified atthe dock, it may be identified by a clerk preparing mailpieces forbarcoding. If shiny mail is identified at step 1000, the shinymailpieces may be transferred to Letter Mail Labeling Machine (LMLM)1044. However, if the shiny mailpieces are not identified at step 1000,the mailpieces may be run through a system running in ISS mode at step1002. The ISS may resolve address 314 at step 1052 and apply barcode 300in POSTNET clear zone 108 at step 1004. If barcode 300 is resolvable atstep 1006, the mailpieces may be automatically sorted by DBCS 1042 atstep 1008 and delivered at step 1010.

However, at step 1006, barcode 300 may not be resolvable due to smudgingof the ink (e.g., the glossy surface may not absorb the ink). At step1012, a determination can be made if sufficient time remains to run themailpieces on LMLM 1044. If time does not permit the mailpieces to betransported to and run on LMLM 1044 and flowed back to an ISS (e.g., ISS1046) for recognition and barcoding, an operator may send the shinymailpieces directly to a manual mail processing section at step 1014.For example, the unresolvable mailpieces may be identified late on Tour3 (the afternoon shift), when cutoff times on the ISS dictateinsufficient time to process on LMLM 1044. Once placed in the manualsort stream, the mailpieces typically remain there for the remainder ofthe trip to their destination (step 1010). This is costly and may slowdown the processing of the mailpieces.

If the address 314 was not resolved at step 1052, the address may beresolved by an RCR or REC at step 1054. If the address is not resolvedat step 1054, the mailpieces would be sent for manual sorting (step1014). However, if the address was resolved by either the RCR or REC,the resolved address associated with the ID Tag could be stored at step1056. The mailpieces could be run at step 1058 on an Output Sub-System(OSS). If the ID Tag is resolvable at step 1060, the address associatedwith the ID Tag can be loaded and barcode 300 may be applied to POSTNETclear zone 108 at step 1062. The mailpieces may be sent to DBCS 1042 atstep 1008 for sorting and delivery at step 1010. However, if the ID Tagwas not resolvable at step 1060, a determination can be made ifsufficient time remains to run the mailpieces on LMLM 1044 at step 1012.

The mailpieces can be transferred to LMLM 1044 if sufficient timeremains to run the mailpieces at step 1016. LMLM 1044 essentiallyover-labels each mailpiece (e.g., places a label over POSTNET clear zone108 or ID Tag clear zone 202). At step 1018, LMLM 1044 may over-label IDTag clear zone 202, POSTNET clear zone 108, or both. For example, themailpieces may be placed on a feeder backwards to allow labels to beapplied to the back of the mailpieces in ID Tag clear zone 202. Thesemailpieces can be re-run on the front so a label can be applied overPOSTNET clear zone 108. Over-labeling both sides (e.g., ID Tag clearzone 202 and POSTNET clear zone 108) can provide a fresh start when bothbarcode 300 and the ID Tag are not resolvable. However, the mailpiecesmay only be run on the front, allowing barcode 300 to be applied toPOSTNET clear zone 108. Over-labeling only the front side may save timeespecially if mail is only going to be run on a MLOCR. Afterover-labeling, the mailpieces may be brought back to ISS 1046 at step1020 and the ID Tag will be applied. At step 1022, a resolve attempt ismade for address 314. If address 314 is resolved, barcode 300 is appliedto POSTNET clear zone 108 at step 1024. The mailpieces may then besorted (using barcode 300) at step 1026 on DBCS 1050 and delivered atstep 1028.

If address 314 cannot be resolved on ISS 1046, another attempt may bemade at resolving the address at step 1030 (which may be on a separatemachine 1048) and barcode 300 may not be applied until the mailpiece isre-run on an OSS. If address 314 is resolvable at step 1030, barcode 300may be applied at step 1032 to POSTNET clear zone 108. The mailpiecescan be run through DBCS 1050 for sorting and delivery at step 1028.However, if address 314 is not resolvable at step 1030 (and possibly ifthere is no ID Tag), the mailpiece may be manually sorted at step 1034and delivered at step 1028.

With reference to FIG. 11, a process according to one embodiment isdescribed that attempts to over-label shiny mailpieces by running themailpieces on a machine that over-labels and applies barcode 300 in onestep, such as a reject encoding machine (REM). Processing the mailpiecesin one step may save time and handling and allow processing of mailpiecerejects late in a given shift that otherwise may not have processed dueto time constraints. In addition, mail may be moved to a downstream DBCSsooner and allows late tour rejects to be re-introduced to the automatedmail stream rather than being relegated to a manual stream.

If shiny mail is identified at step 1100 (e.g., a piece of equipment maybe used to identify the shiny mail by measuring a reflectivity of asurface of the mailpiece), the shiny mailpieces may be transferred toREM 1142. However, if the shiny mailpieces are not identified at step1100, the mailpieces may be run through an ISS at step 1102. The ISS mayresolve address 314 at step 1152 and apply barcode 300 in POSTNET clearzone 108 at step 1104. If barcode 300 is resolvable (step 1106), themailpieces may be automatically sorted by DBCS 1144 at step 1116 anddelivered at step 1118. However, at step 1106, barcode 300 may not beresolvable due to smudging of the ink (e.g., the glossy surface may notabsorb the ink). The unresolvable mailpieces may be transferred to andrun on REM 1142 at step 1108.

If address 314 is not resolved at step 1152, the address may be resolvedby an RCR or REC at step 1154. If the address is not resolved at step1154, the mailpieces may be run on REM 1142 instead of sending themthrough a manual sort. However, if address 314 was resolved at step1154, the resolved address associated with the ID Tag could be stored atstep 1156. The mailpieces could be run at step 1158 on an OutputSub-System (OSS). If the ID Tag is resolvable at step 1160, the addressassociated with the ID Tag can be loaded and barcode 300 may be appliedto POSTNET clear zone 108 at step 1162. The mailpieces may be sent toDBCS 1144 at step 1116 for sorting and delivery at step 1118. However,if the ID Tag was not resolvable at step 1160, the mailpieces may be runon REM 1142 at step 1108.

At step 1110, a label may be placed in POSTNET clear zone 108. Ifaddress 314 is resolved at step 1112 (e.g., if the recognition systemdetermines a full destination barcode 300), the mailpieces may receivebarcode 300 at step 1114 and may be sent to DBCS 1144 for downstreamprocessing (e.g., sorting at step 1116 and delivery at step 1118). Atstep 1120, mailpieces with unresolved addresses may be re-run (this timewith a back side to a labeler) at step 1120 to apply a label to the IDTag clear zone 202 at step 1122.

At step 1124, the mailpieces can be run on ISS 1146. At step 1126, aresolve attempt is made for address 314. If address 314 is resolved,barcode 300 is applied to POSTNET clear zone 108 at step 1128. Themailpieces may then be sorted (using barcode 300) at step 1116 on DBCS1144 and delivered at step 1118. If address 314 can not be resolved onISS 1146, another attempt may be made at resolving the address at step1130 (which may be on a separate machine 1148) and barcode 300 may notbe applied until the mailpiece is re-run on an OSS. If address 314 isresolvable at step 1130, barcode 300 may be applied at step 1132 inPOSTNET clear zone 108. The mailpieces can be run through DBCS 1116 forsorting and delivery at step 1118. However, if address 314 is notresolvable at step 1130, the mailpiece may be manually sorted at step1134 and delivered at step 1118.

Accordingly, cost savings may be achieved when mailpieces are run on REM1142 and receive barcode 300 in one step. In addition, mailpieces thatwould otherwise be sent to for manual processing (e.g., because there isinsufficient time in the tour for LMLM and ISS type processing) may beprocessed on REM 1142 and redirected to DBCS 1144, even if the rejectswere identified late in a shift. Therefore, processing on REM 1142 maysave additional handling on ISS 1140. In addition, mailpieces identifiedlate in the tour may still be processed (using automation) on REM 1142and DBCS 1144 thereby preventing the mailpieces from flowing to manualhandling and all subsequent manual handlings.

1. A method for processing a mail piece rejected from an automatic sorting machine, the reject processing method comprising the steps of: receiving a mail piece rejected from an automatic sorting machine; attempting to resolve a POSTNET barcode affixed on a front side of the received mail piece through a first automated recognition process; if the barcode is not resolvable by the first automated recognition process, attempting to resolve an ID Tag affixed to a back side of the mail piece; if the ID Tag is resolvable, determining whether or not ID Tag data that corresponds to the resolved ID Tag is available; if ID Tag data that corresponds to the resolved ID Tag is available, acquiring the ID Tag data to obtain a resolved address; and sorting the mail piece in accordance with the resolved address.
 2. A reject processing method according to claim 1 and further comprising: if the barcode is resolvable, sorting the mail piece using the resolved barcode; if the barcode is not resolvable, but ID Tag data is resolvable and ID Tag data is available, then, loading ID Tag Data representing resolved address, and sorting using the ID Tag Data; and if barcode is not resolvable, and ID Tag data is not resolvable or corresponding address data is not available, acquiring a new image of at least one side of the mail piece and if a destination address is now resolvable from the new image, placing a new label in POSTNET clear zone, and then printing a machine readable indicia in the new POSTNET Clear Zone, the indicia reflecting the resolved address, and then returning the mail piece for processing by an automated delivery bar code sorter, whereby the mail piece can avoid manual sorting.
 3. A reject processing method according to claim 1 and further comprising: if the ID Tag is not resolvable, attempting to read a destination address of the mail piece on a reject encoding machine; if an address is resolvable, placing a new label in a POSTNET clear zone, printing machine-readable indicia on the new label, the indicia encoding data that corresponds to the resolved address, and then returning the mail piece for processing by an automated delivery bar code sorter, whereby the mail piece can avoid manual sorting. 